JP4702012B2 - Laminate flow forming apparatus, laminated sheet manufacturing apparatus and manufacturing method - Google Patents

Description

  The present invention relates to an apparatus for forming a laminated flow suitable for producing a multilayer film, an apparatus for producing a laminated sheet, and a production method.

  A plurality of types (for example, two types) of sheet materials (typically, molten resin, etc., for the sake of simplicity, the following description will focus on the case where molten resin is used) are supplied to each manifold that receives each molten resin. The molten resin is discharged from each manifold through a plurality of pores and a plurality of slits to form a plurality of molten resin layered flows, and the plurality of molten resin layered flows are joined together to form a multilayered flow. A method of forming a laminated sheet by forming and discharging this laminated flow from a slit-shaped die extending in a direction orthogonal to the lamination direction of each layer of molten resin is known (for example, Patent Document 1). The laminated sheet discharged from the die is used as it is or after that, after being subjected to post-treatment such as stretching.

  A typical example of this laminated sheet manufacturing apparatus is shown in FIG. In FIG. 1, the laminated sheet manufacturing apparatus is supplied by a molten resin introduction tube 1 to which one molten resin A is supplied, a molten resin introduction tube 2 to which the other molten resin B is supplied, and a molten resin introduction tube 1. Supplied by a multilayer feed block 3 as a laminated flow forming apparatus for forming a laminated flow comprising a molten resin A and a molten resin B supplied by a molten resin introduction pipe 2, a conduit 4 through which the formed laminated flow flows, and a conduit 4 From the die 5 and the die 5 that adjust the width and thickness of the laminated flow to predetermined values, discharge the adjusted laminated flow, and form a laminated sheet in which the molten resin A and the molten resin B are alternately laminated. It consists of a casting drum 7 that cools and solidifies the discharged laminated sheet 6. The laminated sheet solidified by the casting drum 7 is usually called an unstretched film 8. The unstretched film 8 is usually sent to a stretching process (not shown) as indicated by an arrow NS and stretched in one direction or two directions to form a multilayer film.

  The multi-layer feed block 3 has passed through a manifold that is coupled to the molten resin introduction pipe 1, a manifold that is coupled to the molten resin introduction pipe 2, and a plurality of slits arranged at predetermined intervals. It has a confluence | merging part which merges the flow of each molten resin. The plurality of slits are divided into two groups, the plurality of slits in one group open to the outlet of the manifold coupled to the molten resin introduction pipe 1, and the plurality of slits in the other group are introduced with the molten resin Opening to the outlet of the manifold coupled to the tube 2. The outlet of the junction is communicated with the conduit 4.

  In general, a resin having a high refractive index and a resin having a low refractive index are supplied to the molten resin introduction tube 1 and the molten resin introduction tube 2, respectively, and a specific wavelength is obtained by alternately laminating each resin with a constant thickness. Broadband interference that reflects or transmits light in a wide wavelength range by laminating the narrowband interference reflection film with the function of reflecting and the thickness of each resin layer sequentially decreasing or increasing at a certain rate in the film thickness direction. Reflective films are known.

  According to the knowledge of the present inventor, it is important to increase the laminating accuracy in order to obtain such a film, but when trying to form a multilayer film using the above-mentioned multilayer feed block, the joining portion of the multilayer feed block It was found that the layer near the wall surface in the stacking direction was not stacked as designed because of the wall surface of the pipe and the wall of the conduit after the feed block.

  In Patent Document 2, the first and second thermoplastic materials that can be extruded are each divided into a plurality of substreams, and the first and second substreams are alternately arranged to form a laminar flow. A mechanical boundary layer is formed with a third thermoplastic material on the outer surface of the flow, the laminated flow is divided into a plurality of portions, the divided laminated flows are moved in positions in the respective bent flow paths, and are joined again. A method of extruding by increasing the number of layers with a simple operation has been proposed. However, with this method, when the target number of layers is large, it is necessary to repeat the mechanical operation many times, reducing the effect of the protective boundary layer, and disturbing the flow due to division, merging, etc. It was difficult to laminate with high accuracy.

  In Patent Document 3, a multilayer flow is constituted by a multilayer feed block having a plurality of slits for the purpose of adjusting the film thickness, and then the multilayer film is passed through the outermost layer flow path branched from the molten resin leading to the multilayer feed block. A method of forming a thick film layer outside the layer has been proposed. FIG. 18 shows a plan view of the feed block of Patent Document 3. The A resin entered from the inlet is introduced into a manifold (not shown) and spreads in the width direction in the manifold, and passes through the pores 39 to the slit 40. Introduce. Further, the B resin entered from the inlet is introduced into the manifold 41 and is expanded in the width direction by the manifold 41, and then flows into the slit 40. In the slit 40, the A resin and the B resin are alternately arranged. Thereafter, the flow is merged at the merge manifold 42 at the exit of the slit 40, and a laminated flow is formed and flows out to the discharge path 43. On the other hand, the A resin entering from the inlet branches off in the middle and flows out from the outlet 45 provided in the discharge passage 43 through the outermost layer conduit 44 provided separately from the passage leading to the manifold (not shown). A thick film layer is formed as the outermost layer of the merged film. However, according to the inventor's knowledge, in this method, after the laminated flow is formed, the wall surface of the discharge channel 43 until the merged manifold 42 and the thick film layer are merged as shown by the line 46 is affected. There is a problem of increasing the complexity and size of the apparatus, such as providing a conduit for use.

  On the other hand, as a method for improving the thinning of the surface layer portion of the multilayer film, the inventors propose in Japanese Patent Application No. 2005-293261 that the thickness of each layer of the multilayer film is measured, and each layer has a target thickness. We have proposed a method to adjust the slit gap and slit length of the corresponding slit, but this method can finally obtain a multilayer film of the target thickness, but the thickness of each layer of the multilayer film There is a problem that the work of measuring and the work of adjusting the slit gap and the slit length of the feed block based on the result are complicated, and in some cases, the feed block needs to be remanufactured, resulting in an increase in cost.

As used herein, the laminated flow is a sheet material laminated in multiple layers until discharged from the die, and the laminated sheet is a sheet material in a state where the laminated flow is discharged from the die.
JP 2003-112355 A JP-T-8-501994 JP 2003-251675 A

  An object of the present invention is to provide a laminated flow forming apparatus, a laminated sheet manufacturing apparatus, and a manufacturing method capable of easily manufacturing a laminated sheet having a thickness of each layer as a target value or a design value.

  Another object of the present invention is to provide a laminar flow forming apparatus and a laminating sheet that can be laminated with high accuracy and are not easily affected by the wall surface of the feed block constituting the multilayer film with a simple apparatus. It is in providing a manufacturing apparatus and a manufacturing method.

  Still another object of the present invention is to provide a laminar flow forming apparatus, a laminating sheet manufacturing apparatus, and a manufacturing method, which can reduce the cost of the slits and the slit lengths of the feed block. It is to provide.

  In order to achieve the above object, the laminated sheet manufacturing apparatus of the present invention has the following configuration.

In other words, it is an apparatus for forming a laminated flow in which a plurality of types of sheet materials are stacked on a plurality of layers larger than the number of the plurality of types, and each sheet material is predetermined so as to pass through corresponding to each layer. A plurality of slits arranged at intervals of each other, and a joining portion that joins each sheet material that has passed through each slit so as to form the laminate to form a laminate flow, and is positioned at both ends of the plurality of slits. In at least one of the slits, the actual slit gap is Ds, the actual slit length is Ls, the virtual slit gap is Dc, and the virtual slit length is Lc.
10 ≦ (Ds ³ / Ls) / (Dc ³ / Lc) ≦ 150 (1)
In order to satisfy the above relationship, there is provided a laminated flow forming apparatus in which the slit gaps and slit lengths of the slits located at both ends of the plurality of slits are set.

  According to a preferred embodiment of the present invention, the actual slit gap Ds of the slits located at both ends of the plurality of slits is configured to be not less than 2 times and not more than 5 times the virtual slit gap Dc. An apparatus for forming a laminar flow is provided. Even if the expression (1) is satisfied, if the slit gap Ds is less than twice the slit gap Dc, the slit length needs to be adjusted and the processing tends to be complicated. Even if the expression (1) is satisfied, if the slit gap Ds is 5 times or more the slit gap Dc, the difference from the slit gap Dc may be too large.

  Further, according to a preferred embodiment of the present invention, the actual slit length Ls of the slits located at both ends of the plurality of slits is configured to be 0.5 times or more and 1 time or less of the virtual slit length Lc. An apparatus for forming a laminar flow is provided. Even if the formula (1) is satisfied, if the slit length Ls is less than 0.5 times the slit length Lc, it is difficult to configure the slit or the flow rate distribution in the slit width direction is poor when actually manufactured. May be. Even if the formula (1) is satisfied, if the slit length Ls is larger than 1 times the slit length Lc, the partition wall constituting the slit becomes longer, the strength of the partition wall decreases, and the processing time becomes longer, resulting in a manufacturing cost. Tend to increase.

  Also, according to a preferred embodiment of the present invention, there is provided the laminated flow forming apparatus, wherein the slit gaps of the plurality of slits other than the slits located at both ends of the plurality of slits are substantially the same. Provided. The slit gaps of the plurality of slits are substantially the same, in one member constituting the plurality of slits, the slit gaps of the plurality of slits through which one sheet material passes are substantially the same, It includes that the slit gaps of the plurality of slits through which the other one sheet material passes are substantially the same. That is, for example, in the member 1, each slit gap of the plurality of slits through which the sheet material A passes is 0.7 mm, and each slit gap of the plurality of slits through which the sheet material B passes is 0.5 mm. . When the slit gaps of the plurality of slits are substantially the same, the slit gaps of the slits are preferably in the range of −5% to + 5% of the common target value.

  Further, according to a preferred embodiment of the present invention, the slit flow of the plurality of slits other than the slits located at both ends of the plurality of slits is 0.1 mm or more and 5 mm or less. An apparatus is provided. If the slit gap is less than 0.1 mm, it may be difficult to control the processing apparatus when processing the slit. When the slit gap exceeds 5 mm, in a feed block having a large number of layers to be laminated, the feed block may become too large in the longitudinal direction (sheet lamination direction), and the pressure of the sheet material flowing through each slit Loss is reduced, and it may be difficult to make the flow rate of the sheet material flowing through each slit uniform.

  Moreover, according to the preferable form of this invention, the number of these slits is 10-1000, The laminated flow formation apparatus characterized by the above-mentioned is provided. The number of slits may be determined according to the required final product form. However, when manufacturing an interference reflection film, a number of slit forming members is required to be 10 or less, which makes it difficult to combine them or reduces the production cost. It is disadvantageous in terms. In addition, when the number of slits is more than 1000, the apparatus is excessively large in the stacking direction, which is not preferable because a stagnant portion is generated or the flow velocity at the slit on the end side becomes nonuniform. More preferably, the number of the plurality of slits is 100 or more and 500 or less.

  Also, according to a preferred embodiment of the present invention, there is provided a plurality of laminated flow forming devices, and the laminated flow forming device includes means for laminating the laminated flows laminated to each other. An apparatus is provided.

  According to another aspect of the present invention, there is provided a laminated sheet comprising: any one of the above-described laminated flow forming devices; and a die for discharging the laminated flow formed by the laminated flow forming device from a discharge port. A manufacturing apparatus is provided.

    According to another aspect of the present invention, a plurality of types of sheet materials are laminated by any one of the above-described laminated flow forming devices to form a laminated flow, and the laminated flow is guided to the die, and the discharge port of the die A method for producing a laminated sheet is provided, wherein the laminated flow is discharged to form a laminated sheet.

  In the present invention, examples of the sheet material include polyolefin resins such as polyethylene, polypropylene, polystyrene, and polymethylpentene, alicyclic polyolefin resins, polyamide resins such as nylon 6 and nylon 66, aramid resins, polyethylene terephthalate, and polybutylene terephthalate.・ Polypropylene terephthalate ・ Polybutyl succinate ・ Polyester resin such as polyethylene-2,6-naphthalate, polycarbonate resin, polyarylate resin, polyacetal resin, polyphenylene sulfide resin, tetrafluoroethylene resin, trifluoroethylene resin, trifluoride Fluorine resin such as ethylene chloride resin, ethylene tetrafluoride-6-fluoropropylene copolymer, vinylidene fluoride resin, acrylic resin, methacrylic resin, poly Acetal resin, polyglycolic acid resin, and the like polylactic acid resin, and melt can be used in fluid reduction. Further, these thermoplastic resins may be homo resins, copolymerized or blends of two or more. Also, in each thermoplastic resin, various additives such as antioxidants, antistatic agents, crystal nucleating agents, inorganic particles, organic particles, thickeners, thermal stabilizers, lubricants, infrared absorbers, ultraviolet absorbers. An agent, a dopant for adjusting the refractive index, and the like may be added.

  In the present invention, the “virtual slit gap” refers to a slit gap on an extension line of a slit gap of a plurality of slits other than the slits located at both ends of the plurality of slits. For example, as shown in FIGS. 19D, 19E, and 19F, when the slit gaps of the slits other than the slits at both ends are distributed as indicated by black circles, the change of the slit gap of these slits is changed. The slit gap when the slit gaps at both ends are estimated according to the law becomes the virtual slit gap Dc (white circle mark). For example, in the case of FIG. 19 (d) or (e) where the change of the slit gap with respect to the slit position (slit number in the figure) is well approximated by a linear function, it is obtained by extrapolation with this linear function. When it can be approximated well by a cubic function as in f), it can be obtained by extrapolation using such an approximate function.

  Further, in the present invention, the “real slit gap” means an actual gap between slits located at both ends of a plurality of slits. For example, in examples such as (d), (e), and (f) in FIG. 19, Ds indicated by black circles at both ends corresponds to this. In the present invention, the “virtual slit length” refers to a slit length on an extension line of a plurality of slits other than the slits located at both ends of the plurality of slits. For example, the case shown by Lc in FIGS. 19A, 19B, and 19C is applicable. The concept of “virtual” is the same as “virtual slit gap”.

  In the present invention, “actual slit length” refers to the actual slit length of the slits located at both ends of the plurality of slits. For example, in an example such as Ls in FIGS. 19A, 19B, and 19C, Ls indicated by black circles at both ends corresponds to this.

  According to the laminated flow forming apparatus, the laminated sheet manufacturing method, and the manufacturing apparatus according to the present invention, it is possible to easily manufacture a laminated sheet having a thickness of each layer as a target value or a design value.

  The laminated flow forming apparatus, the laminated sheet manufacturing method, and the manufacturing apparatus according to the present invention are less susceptible to the influence of the wall surface of the feed block, and can produce a highly accurate laminated sheet.

  In the laminated flow forming apparatus, the laminated sheet manufacturing method and the manufacturing apparatus according to the present invention, the need for adjusting the slit gap and slit length of the feed block is low, and a laminated sheet laminated with high precision can be produced. As a result, the cost associated with the stacking apparatus can be reduced.

  2 to 5 are views relating to the multilayer feed block 11 used in one embodiment of the laminated flow forming apparatus of the present invention. 2 is an exploded perspective view of the multilayer feed block 11, and FIG. 3 is a front view of the slit plate 20 and the junction / discharge path forming member 20a of FIG.

  In addition, in FIG. 1 thru | or FIG. 11, about the member which has the same use and function, the same code | symbol may be attached | subjected.

    2 and 3, the multilayer feed block 11 includes a side plate 21, a side plate 22, and a slit plate 20 sandwiched between the side plate 21 and the side plate 22. The slit plate 20 has a junction / discharge path forming member 20a coupled to the lower part thereof.

    The side plate 21 is provided with a resin A-side manifold 14 extending in the longitudinal direction (X-axis direction shown in FIG. 2), and molten resin A (molten resin A) is supplied into the manifold 14. The resin introduction path 12 is coupled. The side plate 22 is provided with a resin B-side manifold 15 extending in the longitudinal direction (X-axis direction shown in FIG. 2), and molten resin B (molten resin B) is supplied into the manifold 15 into the manifold 15. The resin introduction path 13 is coupled.

    The slit plate 20 is provided with a large number of slits 16 and a large number of slits 17 via partition walls 20b in the longitudinal direction (X-axis direction shown in FIG. 3). The slits 16 and the slits 17 are alternately located via the partition walls 20b. The slits 16 and 17 are engraved in the slit plate 20 with a predetermined length from the bottom surface of the slit plate 20 to the upper surface direction (Z-axis direction shown in FIG. 3). Both side surfaces of each slit 16, 17 are open to both side surfaces of the slit plate 20.

    In the state where the side plate 21, the slit plate 20 and the side plate 22 are assembled, the inlet of each slit 16 opens directly to the outlet of the manifold 14, and the inlet of each slit 17 opens directly to the outlet of the manifold 15. Is done. Further, the openings on the side surfaces other than the entrance of each slit 16 are closed by the wall surfaces of the side plates 21 and 22, and the openings on the side surfaces other than the entrance of each slit 17 are closed by the wall surfaces of the side plates 21 and 22. The inlets of the slits 16 and 17 are directly open to the outlets of the manifolds 14 and 15, and the pores and pore forming members in the conventional multilayer feed block are interposed between the outlets of the manifolds and the inlets of the slits. Not done.

    The resin introduction path 12 is coupled to the resin introduction pipe 1 shown in FIG. 1 and receives supply of the molten resin A from the resin introduction pipe 1. The molten resin A supplied from the resin introduction path 12 into the manifold 14 flows in the manifold 14 in the longitudinal direction of the manifold 14 (X-axis direction shown in FIG. 2) and fills the manifold 14. The molten resin A in the manifold 14 flows into the slits 16 from the entrances of the slits 16 opened in the manifold 14, flows down in the slits 16, and flows out from the exits of the slits 16 to the junction 18. To do.

    The resin introduction path 13 is coupled to the resin introduction pipe 2 shown in FIG. 1 and receives supply of the molten resin B from the resin introduction pipe 2. The molten resin B supplied from the resin introduction path 13 into the manifold 15 flows in the manifold 15 in the longitudinal direction of the manifold 15 (X-axis direction shown in FIG. 2) and fills the manifold 15. The molten resin B in the manifold 15 flows into the slits 17 from the entrances of the slits 17 opened in the manifold 15, flows down in the slits 17, and flows out from the exits of the slits 17 to the junction 18. To do.

    Each sheet-like flow of molten resin A having a cross-sectional shape following the shape of the cross-section (surface including the X-axis and Y-axis shown in FIG. 2) of each slit 16, 17 that has flowed out to the merging portion 18 and the molten resin Each sheet-like flow of B is alternately laminated at the junction 18 to form a laminated flow. This laminated flow flows down the discharge path 19. The lamination direction of the molten resin A and the molten resin B in the laminated flow flowing down the discharge path 19 coincides with the thickness direction of the produced laminated sheet.

    The laminated flow flowing down the discharge path 19 is introduced into the base 5 via the conduit 4 shown in FIG. The laminated flow is widened in a predetermined direction (a direction orthogonal to the lamination direction of the molten resin A and the molten resin B) in the die 5 and discharged from the die 5 as a laminated sheet 6, and the discharged laminated sheet 6 is It is cooled and solidified on the surface of the casting drum 7, sent to the next process (for example, stretching process) as an unstretched film 8, and formed into a multilayer film (not shown).

    4 and 5, the relationship between the slits 16 and the slits 17 located adjacent to each other in the longitudinal direction of the slit plate 20 via the partition wall 20b is shown in an enlarged manner.

    On the upper side of each slit 16, 17, that is, on the upstream part of the second flow path part to be described later, an inclined part 23 that is inclined in the direction toward the downstream of the flow of the molten resin as it is away from the corresponding manifold 14, 15, 24 is formed. In this embodiment, the inclined portions 23 and 24 are formed as inclined portions extending linearly. As shown in FIGS. 4 and 5, the inclined portions 23 and 24 are inclined in directions opposite to each other.

    In the multilayer feed block 11, the molten resin A flows from the manifold 14 into the slits 16 having the inclined portions 23, as indicated by arrows 14a in FIG. Further, the molten resin B flows from the manifold 15 into the slits 17 having the inclined portions 24 as indicated by arrows 15a in FIG.

    By using the inclined portion 23, a flow path of the molten resin A is formed in which the upper portion of the slit 16 is formed only in communication with the manifold 14, and by using the inclined portion 24, the upper portion of the slit 17 is A flow path of the molten resin B formed so as to communicate only with the manifold 15 is constructed.

  FIG. 6 shows a multilayer feed block 11 with no ingenuity at both ends, as in Comparative Example 1 described later, and the slit gap and slit length of the slits located at both ends are the same as the other slit gaps and slit lengths. Is set to FIG. 7 shows a cross section of a multilayer film obtained when a laminated sheet is formed using such a multilayer feed block 11. In the multilayer film 31a of FIG. 7, layers 32a made of resin A and layers 33a made of resin B are alternately laminated. In this case, as described as a problem of the conventional multilayer feed block, the thickness of the layer closer to the surface layer of the multilayer film tends to be thinner due to the influence of the wall surface of the multilayer feed block and the subsequent conduit. This state is shown in the multilayer film 31a of FIG. As a design target of the multilayer film 31a, when the thickness of each layer in the film thickness direction (arrow 30 shown in FIG. 7) is required to be uniform, the multilayer film 31a in which the change in the layer thickness exists in this way is Due to the change in thickness, the reflectance of light having a target wavelength is lowered, or light other than the target is reflected.

The multilayer feed block 11 of this embodiment shown in FIGS. 3 and 9 solves this problem. 3 and 9 is characterized in that the actual slit gap of the slits 16 and 17 arranged at both ends in the X-axis direction shown in FIGS. 3 and 9 is Ds, When the length is Ls, the virtual slit gap is Dc, and the virtual slit length is Lc,
10 ≦ (Ds ³ / Ls) / (Dc ³ / Lc) ≦ 150 (1)
It is a point that satisfies the relationship.

  That is, as in the example shown in FIGS. 19A to 19F, with respect to the slits positioned at both ends of the slit, the actual slit length Lc and the virtual slit gap Dc are expressed by the equation (1). ) At least one of the slits located at both ends so as to satisfy the actual slit length Ls and the actual slit gap Ds.

  By setting the slit gap and slit length of the slits at both ends in this way, the pressure loss of the slit is reduced, and more resin flows than other slits. As a result, the thickness of the layer corresponding to the slit can be increased, and the influence of the wall of the feed block and the conduit can be absorbed by this layer. As a result, the influence of the inner wall surface of the multilayer feed block on the thickness of the layer corresponding to the slits other than both ends can be reduced. In the procedure disclosed in Japanese Patent Application No. 2005-293261 proposed by the present inventor, the layers corresponding to the slits other than both ends are affected by the wall surface and the slit length or slit of each layer is absorbed. Although the gaps are individually adjusted, in the present embodiment, the slits at both ends absorb most of this effect, and therefore the difference is that the design and manufacture of other slits are remarkably facilitated.

Here, if the value of (Ds ³ / Ls) / (Dc ³ / Lc) is less than 10, the thickness of the layer becomes thin and the influence of the wall cannot be absorbed, and the inner layer of the layer becomes thin. . On the other hand, when the value of (Ds ³ / Ls) / (Dc ³ / Lc) exceeds 150, the thickness of the layer becomes too thick, and the thickness of the entire film becomes too large to be handled. More preferably, the value of (Ds ³ / Ls) / (Dc ³ / Lc) is 20 or more and 100 or less.

  Here, the slit lengths Ls and Lc are the lengths of the slits in the vertical direction (Z-axis direction shown in FIG. 3).

  When the top of the slit is inclined, it is the length in the vertical direction (Z-axis direction shown in FIG. 3) of the slit at the center position of the slit width. In the embodiment of FIG. 3, the slit gap of the slits located at both ends is adjusted to satisfy the expression (1), and the slit gap is substantially the same for the other slits.

  A laminated sheet obtained by producing a laminated sheet using a multilayer feed block 11 having slit plates in which slits located at both ends as shown in FIG. 3 are adjusted so as to satisfy the above-mentioned formula (1). Has a laminated structure as shown in FIG. That is, the thickness of the outermost layer of the laminated sheet 31b is thick, and the thickness of the layer 32b made of the resin A and the layer 33b made of the resin B inside is substantially in the film thickness direction (arrow 30 shown in FIG. 8). Therefore, the predetermined target value is uniform.

  The multilayer feed block shown in FIG. 9 shows another embodiment, and is an example that satisfies the formula (1) by adjusting the slit gap and / or the slit length of the slits located at both ends.

  Further, the embodiment described in FIGS. 3 and 9 is a case where the layers other than the layer thickness corresponding to the slits located at both ends target substantially the same thickness in the film thickness direction. It can be applied to a multilayer feed block in which each slit length is set so that the thickness of each of the slits gradually decreases or increases in the film thickness direction.

  Furthermore, the laminated sheet manufacturing apparatus shown in FIG. 10 is an example in which three slit plates 20 (shown as 20-1, 20-2, and 20-3 in FIGS. 10 and 11) are used. FIG. 2 shows a cross-sectional view of the upstream portion of the multilayer feed block 3. The multilayer feed block 3 includes a side plate 21, a slit plate 20-1, a side plate 35, a slit plate 20-2, a side plate 34, a slit plate 20-3, and a side plate from the resin A introduction side toward the resin B introduction side. 22 and the final merger 38 shown in FIG. Resin A that has entered from the inlet flows into the manifold 14-1 from the resin introduction path 12 of the side plate 21 and passes through the resin A introduction path 36 provided in the slit plate 20-1, the side plate 35, and the slit plate 20-2. It flows into the manifold 14-2 of the side plate 34. The resin A that has flowed into the manifold 14-2 flows into the slits by the inclined portions 23-2 and 23-3 of the slit plates 20-2 and 20-3. On the other hand, the resin B entering from another inlet flows into the manifold 15-2 from the resin introduction path 13 of the side plate 22, and the resin B introduction path provided in the slit plate 20-3, the side plate 34, and the slit plate 20-2. 37 and flows into the manifold 15-1 of the side plate 35. The resin B that has flowed into the manifold 15-1 flows into each slit through the inclined portions 24-1 and 24-2. The resin that has flowed into the slits merges at the merging portions 18-1, 18-2, 18-3 of the slit plates 20-1, 20-2, 20-3 and is discharged as a laminar flow 19-1, 19-2, Flow down 19-3. A final merger 38 is provided downstream of the multi-layer feed block 3, and the stacked flows that have flowed down the discharge paths 19-1, 19-2, 19-3 are merged in the stacking direction here, and are connected to the cap 5 through the conduit 4. It is discharged from.

  In this way, the present invention can also be applied when the slit plate 20 is composed of two or more sheets. In this case, the obtained laminated sheet has a thick thickness in addition to the outermost layer. Moreover, when taking such a structure, it is preferable that the layer joined by merging among each laminated stream before merging is comprised with the same resin.

  The measurement methods for the measurement values appearing in the following examples are as follows.

(A) Lamination thickness, number of laminations:
The layer structure of the film was determined by observation with an electron microscope for a sample whose cross section was cut out using a microtome. That is, using a transmission electron microscope (HU-12 type, manufactured by Hitachi, Ltd.), the cross section of the film was magnified 3,000 to 40,000 times, a cross-sectional photograph was taken, the layer configuration and the thickness of each layer Was measured. In the examples, a sufficient contrast was obtained but not performed. However, in some cases, the contrast may be increased using a known dyeing technique.

(B) Reflectance:
A spectrophotometer (U-3410, Spectrophotometer: manufactured by Hitachi, Ltd.) was equipped with an integrating sphere (130-0632, manufactured by Hitachi, Ltd.) having a diameter of 60 mm and an angled 10 ° inclined spacer, and the reflectance was measured. . The band parameter is set to 2 / servo, the gain is set to 3, and the range from 250 nm to 2,600 nm is set to 120 nm / min. The scanning speed was measured. Also, in order to standardize the reflectance, the aluminum oxide plate attached to the device as a standard reflector Was used.

(C) Melt viscosity:
The melt viscosity at a shear rate of 100 (S ⁻¹ ) was measured using a flow tester (CFT-500, manufactured by Shimadzu Corporation). The die used at this time was 1 mm in diameter and the measurement stroke was 10-13. The n number was 3, and the average value was adopted.

[Example 1]
Two types of thermoplastic resin A and thermoplastic resin B were prepared. As the thermoplastic resin A, polyethylene terephthalate (PET) (F20S, manufactured by Toray Industries, Inc.) having a melt viscosity at 280 ° C. of 180 Pa · s was used. As the thermoplastic resin B, polyethylene terephthalate (PE / CHDM · T) (PETG6763, manufactured by Eastman) obtained by copolymerizing 30 mol% of cyclohexanedimethanol having a melt viscosity at 280 ° C. of 350 Pa · s with respect to ethylene glycol was used. These thermoplastic resins A and B were each dried and then supplied to an extruder.

Thermoplastic resins A and B are each melted at a temperature of 280 ° C. with an extruder, measured with a gear pump so that the discharge ratio of resin A / resin B is 2/1, and then introduced through a filter. It was introduced into the multilayer feed block from the tube. As the multilayer feed block, the slit gap corresponding to the resin A is 0.75 mm, the slit gap corresponding to the resin B is 0.6 mm, the slits at both ends correspond to the resin A, and (Ds ³ / Ls) / (Dc ³ / Lc)-is set to about 20 slits, the number of slits into which resin A is introduced including the slits at both ends is 101, and the number of slits into which resin B is introduced is 100. A device was used. The values of (Ls / Lc) and (Ds ³ / Dc ³ ) were set to 1 and about 20, respectively. The slit lengths Ls and Lc were set to be 30 mm. The laminated structure of the laminated film was designed so that layers other than the layers corresponding to the slits at both ends had a uniform thickness between the same resins. Moreover, the shape of a slit shall have an upper inclination part as shown in FIG. 4, FIG.

  After the lamination is completed with the multilayer feed block, the obtained molten resin laminated flow is supplied to the T-die 5 shown in FIG. 1 and formed into a sheet, and then electrostatically applied (DC voltage 8 kV). The film was rapidly cooled and solidified on a casting drum 7 at a temperature of 25 ° C. to obtain an unstretched film.

  The obtained unstretched film was guided to a biaxial stretching machine, preheated with hot air at a temperature of 95 ° C., and then stretched 3.5 times in the longitudinal direction (film longitudinal direction) and in the lateral direction (film width direction). Further, heat treatment was performed with hot air at a temperature of 230 ° C., and at the same time, a relaxation treatment of 5% was performed in the vertical direction, followed by a relaxation treatment of 5% in the lateral direction.

The obtained biaxially stretched multilayer film has a total thickness of 18.1 μm. As shown in FIG. 12, the thickness of the outermost layer of layer number 1 is 1.6 μm, and the other outermost layer has a thickness of 1.6 μm. The layer thickness of surface layer 201 is 1.5 μm, the inner layer is not thinned by the influence of the wall of the feed block and the conduit, the wavelength of the primary reflection peak is 488 nm, the reflectance is 98%, It was a multilayer film excellent in wavelength selectivity.
[Example 2]
10 and 11, the discharge ratio of resin A / resin B is 0.95 / 1, and the multilayer feed block has 134 slits into which resin A is introduced, and resin B Two slit plates with a slit number of 267 with a slit number of 133 introduced, 135 slit numbers with a resin A introduced, and a slit plate with a slit number of 269 with a resin B introduced of 134 slits Resin A was introduced into the slits that were composed of a total of three slits 803 and located at both ends of each slit plate, so that 801 layers were formed after merging. As shown in FIG. 13 (a), the slit gaps other than both ends are 0.5 mm for the slits corresponding to the resin A and the resin B, and after joining, the layers other than the layers corresponding to the both ends of the slit plate are laminated sheets (or As shown in FIG. 13B, the slit length is such that the thickness gradually decreases from the surface layer side to the back surface side of the multilayer film), and the ratio of the surface layer side layer thickness / back surface side layer thickness becomes 0.69. Adjusted. The slits positioned at both ends of each slit plate were set so that the value of (Ds ³ / Ls) / (Dc ³ / Lc) − was 20. The values of (Ls / Lc) and (Ds ³ / Dc ³ ) were set to 1 and about 20, respectively. The slit lengths Ls and Lc were set so that the shorter one was 25 mm. Others were the same as in Example 1, and a multilayer film having a total thickness of 143 μm was obtained. FIG. 14 shows the thickness of each layer. The layer thickness of layer number 1 which is the outermost layer is 3 μm, the layer thickness of layer number 267 is 5.6 μm, the layer thickness of layer number 535 is 6.1 μm, and is the outermost layer. The layer thickness of layer number 801 was 3.1 μm, and all of these layers were resin A. In addition, an inclined structure in which the layer gradually thinned from the surface layer toward the back surface was obtained without thinning the film surface layer portion near the wall surface of the feed block and the conduit. The resulting film has a primary reflection peak wavelength of 900 to 1050 nm, a reflectance of 92%, efficiently reflects broadband near-infrared rays, and almost no high-order reflection is observed in the visible light region. It was an excellent near infrared filter.
[Comparative Example 1]
A multilayer feedblock, the slit gap corresponding to the resin A 0.75 mm, the slit gap corresponding to the resin B and 0.6 mm, the slit ends will correspond to the resin A, as shown in FIG. 6, (Ds ³ Except that the slit was set so that the value of / Ls) / (Dc ³ / Lc) − was 1, it was the same as Example 1. The values of (Ls / Lc) and (Ds ³ / Dc ³ ) were both set to 1. The slit lengths Ls and Lc were set to be 30 mm. The total thickness of the obtained multilayer film is 16.5 μm, and as shown in FIG. 15, the layer thickness 1 of the outermost layer and layer thickness of the layer number 201 are 0.1 μm or less, The near layer is affected by the feed block and conduit wall and is thinner than the design value. The wavelength of the primary reflection peak was a multilayer film with poor wavelength selectivity having a side spectrum on the low wavelength side of the main peak with a reflection spectrum having a wide reflection wavelength bandwidth centered at 551 nm.
[Comparative Example 2]
Comparative Example 1 was the same as the multilayer feed block except that the slits at both ends were set so that the value of (Ds ³ / Ls) / (Dc ³ / Lc) − was 8. The values of (Ls / Lc) and (Ds ³ / Dc ³ ) were set to 1 and 8, respectively. The slit lengths Ls and Lc were set to be 30 mm. The total thickness of the obtained multilayer film is 17 μm. As shown in FIG. 16, the thickness of each layer is 0.4 μm and the layer number 201 is the other outermost layer. The layer thickness is 0.5 μm. Similar to Comparative Example 1, the layer closest to the outermost layer is thinner than the design value due to the influence of the wall of the feed block and the conduit, and the wavelength of the primary reflection peak is centered at 558 nm. As a reflection film having a wide reflection wavelength bandwidth, the multi-layer film has poor wavelength selectivity and has a side peak on the lower wavelength side of the main peak.
[Comparative Example 3]
In Example 2, the multi-layer feed block is composed of two slit plates having a slit number of 267, in which the number of slits into which resin A is introduced is 134, the number of slits in which resin B is introduced is 133, and the number of slits in which resin A is introduced. 133, the number of slits into which the resin B is introduced is 134, and the number of slit plates is 267 (in this case, the resin B is introduced into the slits located at both ends), and a total of three slit plates 801 after joining. It was configured to be a layer. The slits positioned at both ends of each slit plate were set so that the value of (Ds ³ / Ls) / (Dc ³ / Lc) − was 1, and the other cases were the same as in Example 2 except that the multilayer had a total thickness of 72 μm. A film was obtained. The values of (Ls / Lc) and (Ds ³ / Dc ³ ) were both set to 1. The slit lengths Ls and Lc were set so that the shorter one was 25 mm. FIG. 17 shows the thickness of each layer. In each slit plate, the film surface layer near the wall of the feed block and the conduit is thinned, and the wavelength is between 400 and 700 nm, and the reflectance is 50% or less. Was a laminated film with poor optical properties.

  The laminated sheet produced according to the present invention is formed by laminating a plurality of types of sheet materials on a plurality of layers greater in number than this type and then solidifying the molten material. ADVANTAGE OF THE INVENTION According to this invention, the lamination sheet in which the thickness of each layer in the thickness direction of a lamination sheet shows a value as a target value or a design value can be manufactured easily.

The perspective view for demonstrating the manufacturing apparatus and manufacturing process of the lamination sheet which are generally used and are used also for one Embodiment of this invention. The disassembled perspective view of an example of the multilayer feed block used in the manufacturing apparatus of the lamination sheet in one Embodiment of this invention. The front view of the slit board 20 of FIG. 2, and a confluence | merging part / discharge path formation member 20a. The S1-S1 cross section arrow directional view in FIG. The S2-S2 cross-sectional arrow view in FIG. The front view which shows the slit board of the multilayer feed block without a device at both ends. The cross-sectional view of the lamination sheet manufactured using the slit board of FIG. The cross-sectional view of the lamination sheet manufactured using the slit board in one Embodiment of this invention. The front view of another example of the slit board in one Embodiment of this invention. Schematic of the manufacturing apparatus of the lamination sheet which comprised the slit board in one Embodiment of this invention by 2 or more sheets. FIG. 11 is a cross-sectional view of the multilayer feed block of FIG. 10. The graph which shows the measured thickness distribution of each layer which consists of resin A and each layer which consists of resin B of the laminated sheet in Example 1. FIG. 6 is a graph showing the slit gap and slit length of the multilayer feed block used in Example 2. The graph which shows the measured thickness distribution of each layer which consists of resin A and each layer which consists of resin B of the laminated sheet in Example 2. FIG. The graph which shows the measured thickness distribution of each layer which consists of resin A and each layer which consists of resin B of the laminated sheet in the comparative example 1. The graph which shows the measured thickness distribution of each layer which consists of resin A and each layer which consists of resin B of the laminated sheet in the comparative example 2. The graph which shows the measured thickness distribution of each layer which consists of resin A and each layer which consists of resin B of the laminated sheet in the comparative example 3. The top view of the multilayer feed block of patent document 3. FIG. The graph which shows the relationship between the actual slit length Ls, the virtual slit length Lc, the real slit gap Ds, and the virtual slit gap Dc in one Embodiment of this invention.

Explanation of symbols

1: Molten resin introduction tube to which molten resin A is supplied 2: Molten resin introduction tube to which molten resin B is supplied 3: Multi-layer feed block 4: Conduit through which the laminated flow flows 5: Die (T-die)
6: Laminated sheet 7: Casting drum 8: Unstretched film 11: Multi-layer feed block 12, 13: Resin introduction path 14, 14-1, 14-2: Resin A side manifolds 15, 15-1, 15-2: Resin B side manifolds 16, 17: slits 18, 18-1, 18-2, 18-3: merging sections 19, 19-1, 19-2, 19-3: discharge paths 20, 20-1, 20- 2, 20-3: Slit plate 20a: Junction / discharge path forming member 20b: Partition walls 21, 22, 34, 35: Side plates 23, 23-1, 23-2, 23-3, 24, 24-1, 24 -2, 24-3: Inclined portion 30: Film thickness direction 31, 31a, 31b: Laminated sheet (multilayer film)
32, 32a, 32b: Resin A layer 33, 33a, 33b: Resin B layer 36: Resin A introduction channel 37: Resin B introduction channel 38: Final merger 39: Fine pore 40: Slit 41: Manifold 42 : Confluence manifold 43: Discharge path 44: Outermost layer conduit 45: Outlet

Claims (9)

An apparatus for forming a laminar flow in which a plurality of types of sheet materials are stacked in a plurality of layers greater than the number of the plurality of types, wherein the sheet materials pass through the layers corresponding to the layers. And slits located at both ends of the plurality of slits, and a joining portion that joins the sheet materials that have passed through the slits to form a laminate flow. At least one of the above, when the actual slit gap is Ds, the actual slit length is Ls, the virtual slit gap is Dc, and the virtual slit length is Lc,
10 ≦ (Ds ³ / Ls) / (Dc ³ / Lc) ≦ 150 (1)
An apparatus for forming a laminated flow, wherein the slit gaps and the slit lengths of the slits positioned at both ends of the plurality of slits are set so as to satisfy the above relationship.   2. The actual slit gap Ds of slits positioned at both ends of the plurality of slits is configured to be not less than 2 times and not more than 5 times the virtual slit gap Dc. Laminar flow forming device.   2. The actual slit length Ls of slits positioned at both ends of the plurality of slits is configured to be 0.5 to 1 times the virtual slit length Lc. 2. The apparatus for forming a laminated flow according to 1.   The laminated flow forming apparatus according to any one of claims 1 to 3, wherein the slit gaps of the plurality of slits other than the slits located at both ends of the plurality of slits are substantially the same.   The formation of a laminated flow according to any one of claims 1 to 4, wherein a slit gap of the plurality of slits other than the slits located at both ends of the plurality of slits is 0.1 mm or more and 5 mm or less. apparatus.   The number of the plurality of slits is 10 or more and 1000 or less, the laminated flow forming apparatus according to any one of claims 1 to 5.   A laminated flow forming apparatus comprising a plurality of laminated flow forming devices according to any one of claims 1 to 6 and means for laminating the laminated flows formed by the laminated flow forming devices.   An apparatus for producing a laminated sheet, comprising: the laminated flow forming device according to any one of claims 1 to 7; and a die for discharging the laminated flow formed by the forming device from a discharge port.   A plurality of types of sheet materials are laminated by the laminated flow forming device according to any one of claims 1 to 8 to form a laminated flow, the laminated flow is guided to a base, and the laminated flow is discharged from a discharge port of the base, A method for producing a laminated sheet, characterized in that it is a laminated sheet.

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